Insulated shipping containers modified for high-yield fungi production capable in any environment

ABSTRACT

Techniques for generating high-yield fungi production are disclosed. In one particular embodiment, the techniques may be realized as a system for generating high-yield fungi production, the system comprising at least one modular container and a growing system housed within the modular container. The growing system may include a substrate preparation system configured to accept substrate and prepare substrate for pasteurization, a pasteurization system configured to pasteurize prepared substrate received from the substrate preparation system, a draining, cooling, and packing system configured to cool and drain pasteurized prepared substrate from the pasteurization system and to pack pasteurized and cooled substrate into at least one growing container, an inoculation system configured to inoculate the pasteurized and cooled substrate, and a plurality of vertical racks coupled to a ceiling of the modular container and configured to hold the at least one growing container.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit under 35 U.S.C. 119(e) to U.S.Provisional Application No. 62/048,893, entitled “Insulated ShippingContainers Modified for High-yield Fungi Production Capable in AnyEnvironment,” filed Sep. 11, 2014, the contents of which areincorporated herein in their entirety.

BACKGROUND

1. Field

The present disclosure relates to insulated modular containers modifiedfor high-yield fungi production in any environment.

2. Description of Related Art

The need for fresh food, including fungi such as mushrooms, is growingas the population increases and changes in the climate impact growingseasons. The current food supply model is economically andenvironmentally unsustainable because of traditional farming methods andshipping. Operations are usually located in agricultural areas, whichstill require transportation to distribute their produce. These types ofoperations require large upfront costs and rely on larger acreage, andhave high operational costs from spore to sale. For example, sendingfresh food an average of 1500 miles is extremely complicated and addsmajor expense to a customer's supply chain.

Traditional urban/local agriculture is not the solution as it has theproblem of commercial viability for the cultivation of fungi. First,there is limited growing space to meet a high demand. Second, highstart-up costs of fungi growing facilities makes local crop productionimpossible for most businesses. For example, structures must beevaluated by structural engineers and often require additional bracingto support the weight. Operational costs of commercial agriculture alsorequire additional labor and infrastructural costs. Third, urban growingfacilities must survey and address contaminated soil which is furthercostly and time consuming. Offsite operations require additional laborand supplies to reach the same volume, and re-packaging and shipping isan added operating cost.

Traditional fungi growing systems are not the general solution either asmost systems are meant to be installed in agricultural settings, are noteasily transportable, and require years of education and training.

SUMMARY

The present disclosure relates to a compact modular container capable ofhigh-yield fungi production in any environment, that can be operated bythe average person with no prior experience or minimal training.

In some embodiments, the disclosed system can be a system that requiresminimal infrastructure to begin operation and use. The system can thenbe easily expanded in a modular manner to fit and operate in anyenvironment. For example, the system can be configured to expandvertically and/or horizontally to supply a neighborhood or an entirecity.

In some embodiments, the system can be automated and includes asimplified user-interface for anyone to manage and operate. Theuser-interface allows a user to control the internal environment inorder to provide optimal production conditions by eliminatingenvironmental variables.

With a minimal amount of training, this system enables each customer tooperate multiple units, grow food, and make a profit. At a low pricepoint, customers can supplement crops that are shipped from across theworld, and use local high-volume food production to reduce the economicand environmental footprint of food.

Techniques for high-yield fungi production are disclosed. In someembodiments, the techniques may be realized as a system for generatinghigh-yield fungi production. The system may include at least one modularcontainer and a growing system housed within the modular container. Thegrowing system may include a substrate preparation system configured toaccept substrate and prepare substrate for pasteurization, apasteurization system configured to pasteurize prepared substratereceived from the substrate preparation system, and a draining, cooling,and packing system configured to cool and drain pasteurized preparedsubstrate from the pasteurization system and to pack pasteurized andcooled substrate into at least one growing container. The growing systemmay further include an inoculation system configured to inoculate thepasteurized and cooled substrate, a plurality of vertical racks coupledto a ceiling of the modular container and configured to hold the atleast one growing container, a misting system configured to providehumidity and water to the at least one growing container, a climatecontrol system configured to control environmental conditions inside themodular container, a ventilation system configured to provide the atleast one growing container with airflow, and a monitoring systemcoupled to the growing system. The monitoring system may be configuredto monitor and control the pasteurization system, climate controlsystem, ventilation system and misting system in order to maintain a setof conditions prescribed by a user, wherein the monitoring system may beconfigured to provide the user with real-time alerts and access to thegrowing system.

In accordance with other aspects of this particular embodiment, thesystem may further include a lighting system coupled to a ceiling of themodular container and configured to provide artificial light for the atleast one growing container.

In accordance with further aspects of this particular embodiment, thesystem may be further configured to monitor a level of CO₂ within themodular container.

In some embodiments, the system may further be configured to control alevel of CO₂ within the modular container.

In some embodiments, the pasteurization system may include an inner tankand an outer tank, wherein the outer tank includes a heater and a waterdrain and wherein the inner tank is configured to hold substratematerial and the inner tank is positioned within the outer tank, theinner tank containing one or more openings allowing water circulationbetween the inner tank and the outer tank.

In some embodiments, the draining, cooling, and packing system mayinclude an auger at least partially within the inner tank, wherein theauger is operable to agitate substrate materials in the inner tank andto facilitate drainage of water from the inner tank to the outer tankvia at least one opening in the inner tank, a drain in the outer tankoperable to permit drainage of water from the outer tank, an inclineddraining and cooling tube to convey pasteurized substrate from the innertank, a valve connected to the inner tank at a first end and connectedto a lower end of the inclined draining and cooling tube at a secondend, wherein the valve is operable to control a flow of substrate frominner tank to the inclined draining and cooling tube, an auger withinthe inclined cooling and draining tube operable to convey pasteurizedsubstrate from the lower end of the inclined drain and cool tube to anupper end of the inclined drain and cool tube, a drain connected to alower end of the inclined drain and cool tube, the drain operable toreceive water draining from the inclined drain and cool tube, and apacking supply tube connected at a proximate end to the upper end of theinclined drain and cool tube and operable to convey pasteurizedsubstrate from the proximate end to a distal end, the packing supplytube including at least one sealing wall operable to control a flow ofpasteurized substrate through the packing supply tube.

In some embodiments, the inoculation system may include at least oneneedle configured to inoculate the pasteurized and cooled substrate witha liquid culture.

In some embodiments, the inoculation system may include an inclinedhollow tube oriented to inoculate the pasteurized and cooled substratewith grain spawn, the inclined tube having a closure operable to controla flow of the grain spawn to the pasteurized and cooled substrate.

In some embodiments, the modular container may include a plurality ofdividers separating the modular container into a plurality of areas.

In some embodiments, the plurality of areas may include at least twogrowing areas, a preparation area, and an airlock operable to reducecontamination to the growing system from outside of the modularcontainer, wherein the airlock provides the user access to thepreparation area from outside of the modular container.

In some embodiments, the plurality of vertical racks coupled to theceiling of the modular container may be coupled to the ceiling of themodular container via a conveyor.

In some embodiments, the conveyor may support the plurality of verticalracks within a growing area and the conveyor may provide the user accessto the plurality of vertical racks from a preparation area.

In some embodiments, the monitoring system may further include a controlcenter, CPU interface, and wireless interface.

In some embodiments, the monitoring system can be configured to remotelyprovide the user with data on the growing system.

In some embodiments, the monitoring system may be configured to allowthe user to remotely alter the performance of at least one of themisting system, the climate control system, and the ventilation system,in order to maintain the set of conditions prescribed by the user.

In another particular embodiment, the techniques may be realized as amethod for generating high-yield fungi production in any environment.The method may include configuring at least one modular container forfungi cultivation and assembling a growing station within the modularcontainer. Assembling the growing station may include assembling asubstrate preparation system configured to accept substrate and preparesubstrate for pasteurization, assembling a pasteurization systemconfigured to pasteurize prepared substrate received from the substratepreparation system, and assembling a draining, cooling, and packingsystem configured to cool and drain pasteurized prepared substrate fromthe pasteurization system and to pack pasteurized and cooled substrateinto at least one growing container. The techniques may includeassembling an inoculation system configured to inoculate the pasteurizedand cooled substrate in the at least one growing container, assembling aplurality of vertical racks coupled to the ceiling of the modularcontainer and configured to hold the at least one growing container,assembling a misting system configured to provide humidity and water tothe at least one growing container, and assembling a climate controlsystem configured to control environmental conditions inside the modularcontainer. The techniques may also include assembling a ventilationsystem configured to provide the inoculated substrate with airflow andcoupling a monitoring system to the growing system. The monitoringsystem may be configured to monitor and control the pasteurizationsystem, climate control system, ventilation system and misting system inorder to maintain a set of conditions prescribed by a user. Themonitoring system may also be configured to provide the user withreal-time alerts and access to the growing system.

In some embodiments, the techniques may further include providing alighting system coupled to a ceiling of the modular container andconfigured to provide artificial light for the at least one growingcontainer.

In some embodiments, the techniques may further include monitoring alevel of CO₂ within the modular container.

In some embodiments, the techniques may further include controlling alevel of CO₂ within the modular container.

In some embodiments, the pasteurization system may include an inner tankand an outer tank, wherein the outer tank may include a heater and awater drain and wherein the inner tank may be configured to holdsubstrate material and the inner tank may be positioned within the outertank, and the inner tank may contain one or more openings allowing watercirculation between the inner tank and the outer tank.

In some embodiments, the draining, cooling, and packing system mayinclude an auger at least partially within the inner tank. The auger maybe operable to agitate substrate materials in the inner tank and tofacilitate drainage of water from the inner tank to the outer tank viaat least one opening in the inner tank. The draining, cooling, andpacking system may also include a drain in the outer tank operable topermit drainage of water from the outer tank, an inclined draining andcooling tube to convey pasteurized substrate from the inner tank, and avalve connected to the inner tank at a first end and connected to alower end of the inclined draining and cooling tube at a second end, Thevalve may be operable to control a flow of substrate from inner tank tothe inclined draining and cooling tube. The draining, cooling, andpacking system may include an auger within the inclined cooling anddraining tube operable to convey pasteurized substrate from the lowerend of the inclined drain and cool tube to an upper end of the inclineddrain and cool tube, a drain connected to a lower end of the inclineddrain and cool tube, the drain operable to receive water draining fromthe inclined drain and cool tube, and a packing supply tube connected ata proximate end to the upper end of the inclined drain and cool tube.The packing supply tube may be operable to convey pasteurized substratefrom the proximate end to a distal end. The packing supply tube mayinclude at least one sealing wall operable to control a flow ofpasteurized substrate through the packing supply tube.

In some embodiments, the inoculation system may include at least oneneedle configured to inoculate the pasteurized and cooled substrate witha liquid culture.

In some embodiments, the inoculation system may include an inclinedhollow tube oriented to inoculate the pasteurized and cooled substratewith grain spawn. The inclined tube may include a closure operable tocontrol a flow of the grain spawn to the pasteurized and cooledsubstrate.

In some embodiments, the modular container may include a plurality ofdividers separating the modular container into a plurality of areas.

In some embodiments, the plurality of areas may include at least twogrowing areas, a preparation area, and an airlock operable to reducecontamination to the growing system from outside of the modularcontainer, wherein the airlock provides the user access to thepreparation area from outside of the modular container.

In some embodiments, the plurality of vertical racks coupled to theceiling of the modular container may be coupled to the ceiling of themodular container via a conveyor.

In some embodiments, the conveyor may support the plurality of verticalracks within a growing area and the conveyor may provide the user accessto the plurality of vertical racks from a preparation area.

In some embodiments, the monitoring system may further include a controlcenter, CPU interface, and wireless interface.

In some embodiments, the monitoring system may be configured to remotelyprovide the user with data on the growing system.

In some embodiments, the monitoring system may be configured to allowthe user to remotely alter the performance of at least one of themisting system, the climate control system, and the ventilation system,in order to maintain the set of conditions prescribed by the user.

In another embodiment, the techniques may be realized as a method forhigh-yield fungi production in any environment. The method may includepreparing substrate for pasteurization using an apparatus for choppingthe substrate, providing the chopped substrate to a pasteurizationapparatus, and pasteurizing the substrate using a heated solution in apasteurization container. The pasteurization container may be configuredto receive a specified amount of substrate, a specified amount ofpasteurization solution, and to heat the substrate for a specifiedduration. The techniques may further include automatically providing thepasteurized substrate to a draining and cooling apparatus, inoculatingcooled and drained substrate with at least one of: a grain spawn and aliquid culture, packing pasteurized and inoculated substrate into atleast one growing bag, placing the at least one growing bag on avertical rack coupled to a ceiling of a modular container configured toprovide a fungi growing environment, and automatically monitoring andmanaging environmental conditions of the modular container.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will further be described by way of example andwith reference to the following drawings, in which:

FIG. 1A shows a perspective sectional view of an illustrative growingcontainer according to an embodiment of the disclosure.

FIG. 1B shows a perspective sectional view of an illustrative growingcontainer according to an embodiment of the disclosure.

FIG. 1C shows a perspective sectional view of an illustrative growingcontainer according to an embodiment of the disclosure.

FIG. 1D shows a perspective sectional view of an illustrative growingcontainer according to an embodiment of the disclosure.

FIG. 1E shows a perspective sectional view of an illustrative growingcontainer according to an embodiment of the disclosure.

FIG. 1F shows a perspective sectional view of an illustrative growingcontainer according to an embodiment of the disclosure.

FIG. 1G shows a perspective sectional view of a growing area of anillustrative growing container according to an embodiment of thedisclosure.

FIG. 1H shows a perspective sectional view of a substrate storage areaan illustrative growing container according to an embodiment of thedisclosure.

FIG. 1I shows a perspective sectional view of a growth preparation areaof an illustrative growing container according to an embodiment of thedisclosure.

FIG. 2 shows an illustrative flow diagram of a process for growing fungiaccording to an embodiment of the disclosure.

FIG. 3 shows an illustrative flow diagram of monitoring a process forgrowing fungi according to an embodiment of the disclosure.

FIG. 4A depicts a layout of areas in a growing container according to anembodiment of the disclosure.

FIG. 4B depicts an alternative layout of areas in a growing containeraccording to an embodiment of the disclosure.

FIG. 4C depicts another alternative layout of area in a growingcontainer according to an embodiment of the disclosure.

FIG. 5 depicts a substrate preparation system according to an embodimentof the disclosure.

FIG. 6A illustrates a substrate pasteurization system according to anembodiment of the disclosure.

FIG. 6B illustrates a substrate pasteurization tank according to anembodiment of the disclosure.

FIG. 6C illustrates a substrate pasteurization tank according to anembodiment of the disclosure.

FIG. 6D illustrates a substrate pasteurization tank lid according to anembodiment of the disclosure.

FIG. 6E illustrates a substrate pasteurization tank lid according to anembodiment of the disclosure.

FIG. 6F illustrates a substrate pasteurization tank lid according to anembodiment of the disclosure.

FIG. 6G illustrates a substrate pasteurization tank orifice adapteraccording to an embodiment of the disclosure.

FIG. 6H illustrates a substrate pasteurization tank orifice adapteraccording to an embodiment of the disclosure.

FIG. 6I illustrates a substrate pasteurization tank orifice adapteraccording to an embodiment of the disclosure.

FIG. 6J illustrates a substrate pasteurization tank substrate supplyduct according to an embodiment of the disclosure.

FIG. 6K illustrates a substrate pasteurization tank agitator accordingto an embodiment of the disclosure.

FIG. 6L illustrates a substrate pasteurization tank agitator accordingto an embodiment of the disclosure.

FIG. 6M depicts a cross-sectional view of a substrate pasteurizationtank according to an embodiment of the disclosure.

FIG. 7 illustrates an alternative substrate pasteurization systemaccording to an embodiment of the disclosure.

FIG. 8 illustrates another alternative substrate pasteurization systemaccording to an embodiment of the disclosure.

FIG. 9 depicts a substrate preparation and packaging system according toan embodiment of the disclosure.

FIG. 10 depicts a substrate preparation and packaging system accordingto an alternative embodiment of the disclosure.

FIG. 11 shows an illustrative flow diagram of process for preparingsubstrate according to an embodiment of the disclosure.

FIG. 12 depicts a container for pasteurizing substrate according to anembodiment of the disclosure.

FIG. 13 depicts a containers for water according to an embodiment of thedisclosure.

FIG. 14 depicts an alternative container for pasteurizing substrateaccording to an embodiment of the disclosure.

FIG. 15 is a diagram showing an arrangement of containers for water,pasteurization, water reclamation, and misting according to anembodiment of the disclosure.

FIG. 16 shows a schematic arrangement of a pasteurization container, asubstrate cooling and drying apparatus, and a substrate packing supplypassage according to an embodiment of the disclosure.

FIG. 17 depicts an inoculation and packing apparatus according to anembodiment of the disclosure.

FIG. 18A depicts a grow container control system according to anembodiment of the disclosure.

FIG. 18B depicts a grow container electrical diagram according to anembodiment of the disclosure.

FIG. 19A depicts a growth medium support structure according to anembodiment of the disclosure.

FIG. 19B depicts a growth medium support structure according to anembodiment of the disclosure.

FIG. 20 depicts a growth medium support structure conveyor arrangementaccording to an embodiment of the disclosure.

FIG. 21 depicts an alternative growth medium support structure conveyorarrangement according to an embodiment of the disclosure.

FIG. 22 shows examples of data that can be remotely monitored andcontrolled via the illustrative monitoring system, all according toembodiments of the disclosure.

FIG. 23 shows further examples of data that can be remotely monitoredand controlled via the illustrative monitoring system, all according toembodiments of the disclosure.

FIGS. 24A, 24B, 24C, and 24D show examples of additional data that canbe remotely monitored and controlled via the illustrative monitoringsystem, all according to embodiments of the disclosure.

FIGS. 25A-25B show examples of further data that can be remotelymonitored and controlled via the illustrative monitoring system, allaccording to embodiments of the disclosure.

FIG. 26 shows a perspective view of an embodiment of a ventilationsystem.

DESCRIPTION

The present disclosure is directed to a system and method for modifyinga modular container for high-yield fungi production in any environment.In one embodiment, a system can expand to fit any space, and besubsequently started and operated by an individual with minimal trainingAnother embodiment allows the user to monitor and modify the environmentand feeding conditions in order to provide optimal growth conditions forthe specific type of fungi being grown.

FIG. 1A shows a perspective sectional view of an illustrative growingcontainer 102 according to an embodiment of the disclosure. In anotherembodiment, container 102 can also include a water reclamation system(not shown). Container 102 can be a recycled shipping container withstandard transnational grade intermodal perishable food-grade insulationfoam sandwiched between the steel walls of container 102. Container 102may also be sealed in order to create a solid modular frame forexpansion, as well as a controlled growing environment for fungi.

In some embodiments, container 102 can be modified to include a solararray 104 to harness solar energy and store it in a converter orbatteries for later use. One of ordinary skill in the art wouldrecognize that other energy efficient solutions, such as insulationpaint or additional crops on top of and around container 102, can alsobe incorporated into container 102 to make it even more energyefficient. Other renewable energy technologies, such as forms of solarand wind power, could also be added to increase functionality. All ofthese components can be relocated within the unit, outside the unit, ontop of the unit, or next to the unit, to increase space, efficiency,and/or ease of access.

As depicted in FIG. 1A, container 102 may include one or more vessels118, 120 and 122. According to some embodiments, vessel 120 may storesubstrate for preparation for growth of fungi. Substrate may include oneor more mediums capable of accepting fungi spore and supporting growthof fungi (e.g., straw, wood chips, sawdust, cardboard, coffee grounds,and other cellulose-based substrates.) Vessel 118 may store substrateduring a pasteurization process. Vessel 122 may store water or otherliquids for misting or other application to fungi in container 102.Container 102 may be subdivided into a plurality of different areas,such as, for example, grow area 104, grow area 106, airlock 108, andpreparation area 110. Grow areas may contain conveyors, carousels, orother transportation systems for moving hanging growing modules. Forexample, conveyor 112 may support one or more hanging growing modules116. Conveyor 112 may be powered by a motor 114, which may provide forthe movement of one or more hanging growing modules 116 Hanging growingmodules 116 may contain one or more platforms for carrying substrate forgrowing fungi. Other systems and/or components (not shown) may beincluded in container 102 (e.g., an LED lighting system, an irrigationsystem, a ventilation system, etc.). In order to control the internalenvironment of container 102, the system can include a climate controlsystem that can measure and control humidity, carbon dioxide levels,temperature, and other related environmental factors.

In some embodiments, the system also can include a ventilation systemhaving a main fan and a plurality of intermittent fans. Intermittentfans may be optional, additional fans which can be installed (e.g.,every ten to twenty feet) to allow for additional air circulation. Theventilation system can include main fans, intermittent fans, and/or airvents. External air may be taken in by main fans at one end of container102, and may be pushed through container 102 via intermittent fans, andthen exhausted from container 102 at the opposite end. Intake air may berun through several High Efficiency Particulate Air (HEPA) charcoalfilters at main fans and exhaust air may be run through micro screencharcoal filters. In some embodiments, ventilation system may utilizeadditional air vents coupled to a ceiling of container 102 to create adual airflow system. Dual airflow system may be generated from thevertical air flow from vents 504 and horizontal air flow from main fans502 and intermittent fans 1302. In other embodiments of the disclosure,additional fans and/or vents may be positioned in or on the floor ofcontainer 102 to blow air vertically from the ground up between rows ofhanging growing modules. Providing air flow in more than one directionis preferable in order to further create actual conditions that fungiwould encounter outdoors. Furthermore, the chaotic and random air flowpatterns that are generated stimulate the fungi and force them to growstronger and denser stems. In embodiments of the disclosure, thevertical configuration of the racks along with the added vertical flowof air allows for air flow through the fungi and maintains a constantflow. Furthermore, the added vertical air flow, on top of the existinghorizontal air flow, directly cools lighting while also providing anideal level of stress to the fungi.

In one embodiment, assembly of the unit starts with obtaining a new orused insulated shipping container 102 that implements vents on each doorand preferably has vents on each wall. In one example, there is anaverage of one vent per ten feet. An electrical panel, such as a 200amp, 240 volt panel, can be coupled to one of the walls of container 102for power. A Heating, Ventilation and Air Conditioning (HVAC) or otherclimate control unit and main fan can also be coupled to one of thewalls of container 102. Intermittent fans can be installed every ten totwenty feet to allow for proper air circulation.

FIG. 1B shows a perspective sectional view of an illustrative growingcontainer according to an embodiment of the disclosure. The illustrativegrowing container of FIG. 1B may facilitate proper processing andpreparation of substrate or growth medium. The illustrative growingcontainer of FIG. 1B may also facilitate proper growing conditions(e.g., by eliminating or reducing environmental variables).

Different rooms (e.g., different shipping containers or divisions ofshipping containers) may distinctly segment different stages of aproduction process (e.g., a fungi production process may be segmentedinto a substrate preparation area, a planting preparation area, agrowing area, etc.). Growing containers may include several differentcontainer architectures—the straight layout of FIG. 1B is an embodiment.The growing container in FIG. 1B may use two containers placed end toend. One container (e.g., container 126) may consist primarily of one ormore grow rooms (e.g., for fungi) and the other (e.g., container 124)may consist primarily of one or more subsystems to prepare growth medium(or substrate).

In some embodiments, these two containers could completely separate,allowing a single prep shipping container to service multiple grow roomshipping containers. In some embodiments, there may be one or moreshared components between a grow shipping container and prep shippingcontainer.

Room 132 of FIG. 1B may be for the storage of water and growth mediumraw material (e.g., straw) Room 132 may also provide space for thechopping and loading of the growth medium or substrate into a tank. Room132 may be segmented from the rest of the growing container in order toisolate the messy nature of the work. Room 132 may contain raw materials133.

Room 128 may be a prep room. Room 128 may contain pasteurization,bagging and/or inoculation equipment. A majority of the physical labormay occur in room 128, which may be where the substrate is prepared forthe grow rooms of container 126. There may be an “airlock” 130 from thisroom to the outside, allowing entry in a moderately sterile manner.

The one or more rooms of container 126 may be grow rooms for the growthof fungi. Each room may be independently environmentally controlled forboth humidity and temperature. Fungi grow bags from a prep room may bearranged on “grow trees” that hang from automatic carousels. Anexemplary grow tree is illustrated in FIGS. 19A and 19B. Carousels mayfacilitate access to a crop from a single operating point.

The primary functional element of the grow room is the environmentalcontrol. Each grow container may contain a plurality of grow rooms(e.g., two). The rooms can be long and skinny, and the carousel may be along oval down the length of the room. Each room can have independentenvironmental control.

A single controller can be used for both rooms or multiple controllersmay be used. A controller monitor the temperature, humidity and CO₂ inone or more grow rooms. Each of these measurements may controls anindependent “actuator” of some kind:

1. The temperature may controls the AC units—there may be a mini splitAC unit in each grow room.

2. The humidity may controls the misting system—there may be anindependent mister in each grow room.

3. The CO₂ sensor may controls the ventilation fan, which may also beindependent for each room,

In addition, the grow lights may turn on and off at different times inthe grow cycle. This could be controlled or manual.

FIG. 1C shows a perspective sectional view of an illustrative growingcontainer according to an embodiment of the disclosure. As illustratedin FIG. 1C, containers 134A and 134B may be for water and/or wastestorage which may supply water to and/or receive waste frompasteurization tank 136. Misting pump 140 may supply one or more mistinglines 142 to provide water to a fungi group and/or to add humidity to agrowing environment. Air conditioner 144 may provide climate control toan environment.

FIG. 1D shows a perspective sectional view of an illustrative growingcontainer according to an embodiment of the disclosure. As illustratedin FIG. 1D, water heater 146 may provide temperature controlled waterfor pasteurization, which may be supplied by pump 148 to apasteurization tank. Conveyor control unit 150 may facilitate movementof grow trees under one or more misting lines 142.

FIG. 1E shows a perspective sectional view of an illustrative growingcontainer according to an embodiment of the disclosure. As illustratedin FIG. 1E, a growing container may contain one or more work lights(e.g., work lights 156, 158, 164 and 166). A growing container may alsocontain one or more ventilators (e.g., ventilators 160, 162, 168, and182). A preparation room may contain an agitator motor 174 (e.g., anauger motor for an auger of a pasteurization tank), heater andcontroller elements 176, a substrate conveyor 178, and a bagger 180.Grow rooms may contain conveyors 170 and 184 for moving one or more growtrees throughout a grow room. One or more light strips (e.g., LED strips186A and 186B) may be arranged around a grow room. A grow room maycontain air conditioners 172 and 188 to facilitate temperature controlwithin a grow room.

FIG. 1F shows a perspective sectional view of an illustrative growingcontainer according to an embodiment of the disclosure. As illustratedin FIG. 1F, a bagger 180 may contain inoculator 190 for injecting aliquid culture into a substrate (e.g., injecting a liquid culture into agrow bag at one or more locations). Wall switch 192 may control asubstrate conveyor, a pasteurization agitator (e.g., an auger) or othercomponents. Control box 194 may contain relays to one or more additionalcomponents (e.g., A/C units, carousels, pumps, lights, etc.).

FIG. 1G shows a perspective sectional view of a growing room of anillustrative growing container 126 according to an embodiment of thedisclosure. Properly prepared substrate may be packaged into sealed bagsin a prep room and loaded onto one or more grow trees 196 suspended fromcarousels 170 and 184. A grow room may then be darkened. Temperature andhumidity may be maintained at a particular set point as the fungi spawnpropagate (e.g., into mycelium) and takes over the substrate.

After a period of time (e.g., about three weeks), conditions inside oneor more grow rooms may be rapidly changed (e.g., the temperature may bedropped, the humidity increased, and the lights turned on). At this timean operator may also punch holes in the grow bags at the locations wherefungi will sprout from.

Several days later, the fungi may sprout and may be harvested. Thecarousels may allow the fungi to be taken out (e.g., from a singleoperator position) and carried out through a prep room airlock. Forexample, strips dividing rooms may be tied aside for this operation.

FIG. 1H shows a perspective sectional view of substrate storage area 132of an illustrative growing container according to an embodiment of thedisclosure. Substrate storage room 132 may serve several functions.Substrate storage room 132 may store substrate raw materials such assubstrate material 133 and containers 134 (e.g., straw and water).Substrate storage area 132 may also provide an isolated area for thepreparation of substrate (e.g., loading and chopping) which may reducemess and contamination to other areas of a growing container. One end ofsubstrate storage room 132 may open away from the rest of a growingcontainer to the outside environment (e.g., through regular double doorson a freight container). Substrate storage area 132 may be lit by twowork light fixtures on the ceiling with a light switch placed by thedoor, and is ventilated by a fan and filter system. Substrate storagearea 132 may be completely sealed from the rest of the unit (e.g., toget into a prep room it may be necessary to go outside and back throughthe airlock on the side of the prep room). Substrate (e.g., straw) maybe stored in the side of the room closest to the double doors. It maysimply be stacked in bale form.

A substrate chopper 199 may be placed on the growing container side ofsubstrate storage area 132. One or more different types of chopping orsubstrate preparation systems may be used to prepare raw substratematerials (e.g., straw). For example, a chopper/blower combination maybe used to blow the chopped straw directly into the pasteurization tankthrough the scoop on the tank and the chopper hose. Substrate storagearea 132 may be vented (or one or more doors may be open) when running achopper inside. In some embodiments, if there is a pre-chopped substrateavailable then a chopper can be replaced with a step ladder and a scoopon a pasteurization tank can be widened to allow a user to place thechopped substrate directly in the tank.

Water can be stored in one or more stacked containers 134 (e.g., IBC 275gallon totes) inside substrate storage area 132. These containers can beplumbed by their drain lines to a system water supply pump in a preproom. In some embodiments multiple containers may be used for waterstorage and drain water may be sent from the pasteurization tank to anoutside drain (e.g., through either the wall of the growing container oran airlock door).

FIG. 1I shows a perspective sectional view of a growth preparation arearoom 128 of an illustrative growing container according to an embodimentof the disclosure. Prep room 128 may contains one or more componentsused to turn chopped substrate into fungi-ready substrate bags, packedwith grain spawn. Prep room 128 may also have the support systems forother rooms, including ventilation and work lighting. There can be anairlock door 130 to the outside, and a foot wash can be placed in thisairlock if desired.

According to an embodiment, the steps to use prep room 128 may include:

1. Chopped substrate is injected into the pasteurization tank from thesubstrate storage area 132 (e.g., by hand or using a chopper/blower).

2. Hot water is injected into the pasteurization tank (e.g., from apropane hot water heater), covering the chopped substrate. As the waterheight rises, a controller kicks on (e.g., a controller from WatlowElectric Manufacturing Company) and the internal tank heating elementskeep the water at a constant preset temperature.

3. An auger motor is turned backwards intermittently during thepasteurization time to ensure that the entire tank is kept at arelatively even temperature.

4. When finished, the drain valve at the bottom of the tank is openedand the auger is turned constantly backwards to keep the drain clear ofsubstrate.

5. As the water finishes draining, a main valve on the pasteurizationtank is opened, and the auger is switched to the forward direction(forcing the substrate out onto the conveyor).

6. The conveyor is turned on, as is the bagging machine. The baggingmachine fills the bags with chopped, moist substrate.

7. The inoculation subsystem may sit on top of the bagger, passivelyspreading grain spawn into the substrate as it is bagged.

8. After a bag is filled, it is sealed with a seam sealer and placed onthe grow room carousel.

FIG. 2 shows an illustrative flow diagram of a process for growing fungiaccording to an embodiment of the disclosure. At block 202, the method200 for fungi growing may begin.

At block 204, substrate preparation may begin. Substrate may include oneor more mediums capable of accepting fungi spore and supporting growthof fungi (e.g., straw, wood chips, sawdust, cardboard, coffee grounds,and other cellulose-based substrates.) Substrate preparation may includechopping, cutting, blowing, and/or grinding substrate into a growthmedium.

At block 206, substrate may be pasteurized. Pasteurization may include,for example, soaking a substrate in a heated liquid (e.g., water heatedbetween 160 and 180 degrees, steam heat, dry heat, soaking in a solutionof peroxide, etc.). Pasteurization may reduce an amount of harmfulbacteria in a substrate and improve fungi production.

At block 208, substrate may be drained and cooled. Draining and coolingmay use an inclined passage, an auger, or another method of conveying,draining, and/or cooling substrate.

At block 210, a type of fungi culture may be selected. Selection maydepend on a type of fungi cultivation desired. For example, a grainspawn may be selected or a liquid spawn may be selected. If a grainspawn is selected the method may continue at block 212. If a liquidspawn is selected the method may continue at block 214. At block 212, asubstrate may be inoculated with a grain culture. At block 214, asubstrate may be inoculated with a liquid culture.

At block 216, one or more growth preparation steps may be taken. Forexample, one or more growth parameters may be set. Inoculated substratemay be loaded into one or more hanging growing modules. A grow cycle maybegin.

At block 218, one or more growing conditions may be monitored. It may bedetermined whether one or more growing parameters are in a specifiedrange. If one or more parameters are not in a specified range, themethod may continue at block 220. If grow parameters are in a specifiedrange, the method may continue at block 224.

At block 220, an alert may be sent to a user. Alerts may include one ormore of an email, a text message, a web posting, a log file, a phonemessage, or other forms of electronic communication. An alert mayindicate a triggering event (e.g., a parameter is outside of a specifiedrange—such as a temperature too hot or a CO₂ level too low). An alertmay provide one or more suggested remedies or may provide access to acontrol for adjusting environmental conditions (e.g., a link to a userinterface for adjusting one or more of temperature, humidity, CO₂,etc.).

At block 222, conditions may be adjusted. For example, an amount of CO₂,an amount of water, a temperature, an amount of light, or anotherenvironmental condition may be adjusted.

At block 224, it may be determined whether a grow cycle is complete. Thedetermination may be performed based on one or more factors such as, forexample, an expiration of a time period, a measurement of fungi growth,an optical measurement, and/or a visual inspection. If a grow cycle isnot complete the method may return to block 218. If a grow cycle iscomplete the method may continue at block 226.

At block 226, fungi may be harvested. At block 228, the method 200 mayend.

FIG. 3 shows an illustrative flow diagram of monitoring a process forgrowing fungi according to an embodiment of the disclosure. At block302, the method 300 for monitoring growing fungi may begin.

At block 304 a desired temperature range may be set for one or moreareas of a growing container. According to some embodiments, differenttemperature ranges may be set for different areas (e.g., growing rooms)of a growing container.

At block 306 a desired humidity range may be set for one or more areasof a growing container. According to some embodiments, differenthumidity ranges may be set for different areas (e.g., growing rooms) ofa growing container.

At block 308 a range of acceptable levels of light may be set. Accordingto some embodiments, no light may be permitted, only light within aspecified wavelength may be permitted, or a low level of light may bepermitted. For example, a blue LED lighting system may be used.

At block 310 a range of acceptable CO₂ levels may be set. CO₂ levelsand/or other parameters may be set according to a type and or amount offungi cultivated.

At bocks 312 through 324 the method may determine whether one or moreparameters are within a specified range. Parameter levels may varydepending on a type of fungi cultivated. At block 312 if temperature isnot within a specified range the method may continue at block 314. Atblock 314, the temperature may be adjusted. If temperature is within aspecified range the method may continue at block 316.

At block 316 if humidity is not within a specified range the method maycontinue at block 318. At block 318, the humidity may be adjusted. Ifhumidity is within a specified range the method may continue at block320.

At block 320 if CO₂ is not within a specified range the method maycontinue at block 320. At block 320, the CO₂ may be adjusted. If CO₂ iswithin a specified range the method may continue at block 324.

At block 324 if other parameters (e.g., fungi growth amount, lightlevel, etc.) are not within a specified range the method may continue atblock 326. At block 326, the parameters may be adjusted. If parametersare within a specified range the method may continue at block 328. Atblock 328, it may be determined whether a grow cycle is complete. If agrow cycle is not complete the method may return to block 312. If a growcycle is complete the method may end at block 330.

FIG. 4A depicts a layout of areas in a growing container according to anembodiment of the disclosure. Grow container 402 may contain adjoininggrow areas 404 and 406, preparation area 410 and airlock 408. Grow areasmay hold fungi in hanging growing modules. Hanging growing modules mayprovide vertical racks, shelves, or platforms for supporting one or morecontainers or bags of pasteurized and inoculated substrate (e.g., growbags). As described in further detail below with reference to FIG. 19A,hanging growing modules may provide a connection point for attaching toa ceiling or an overhead conveyor and may provide a dense growingconfiguration. Preparation room 410 may provide space and/or apparatusfor loading inoculated substrate into one or more bags or othercontainers and onto hanging growing modules. Airlock 408 may provide anentrance to grow container 402 designed to reduce contamination to growareas. An arrangement of growing areas may depend on crop yield, fungito be grown, reducing a risk of contamination, providing for improvedoperator access to fungi, and other factors.

FIG. 4B depicts an alternative layout of areas in a growing containeraccording to an embodiment of the disclosure. Grow container 412 maycontain grow areas 414 and 420 separated by preparation area 416 andairlock 418.

FIG. 4C depicts another alternative layout of area in a growingcontainer according to an embodiment of the disclosure. Grow container422 may contain grow areas 424 and 430 arranged end to end. Growcontainer 422 may also contain preparation area 426 and airlock 428.

Substrate Preparation and Pasteurization

Substrate may include one or more mediums capable of accepting fungispore and supporting growth of fungi (e.g., straw, wood chips, sawdust,cardboard, coffee grounds, and other cellulose-based substrates.Preparation of substrate may include chopping, slicing, grating,shedding or otherwise preparing the growth medium to support growth offungi. Pasteurization may include, for example, soaking a substrate in aheated liquid (e.g., water heated between 160 and 180 degrees, steamheat, dry heat, soaking in a solution of peroxide, etc.). Pasteurizationmay reduce an amount of harmful bacteria in a substrate and improvefungi production.

FIG. 5 depicts a substrate preparation system according to an embodimentof the disclosure. Pasteurization tank 504 may be on top of growcontainer 502, adjoining grow container 502, or in close proximity togrow container 502. Pasteurization tank 504 may contain an outer tankand an inner tank 506. Inner tank 506 may receive substrate (e.g.,chopped straw) from a conduit. The conduit may be connected to blower510 or another apparatus for substrate conveyance. Blower 510 may movechopped, cut, or shredded substrate from chopper 508 of substrate tank504 to inner tank 506. Chopped substrate in inner tank 506 may bepasteurized. After pasteurization, chopped and pasteurized substrate maybe received by draining and cooling conduit 512.

According to some embodiments, the substrate starts as bales of uncutstraw. Chopper 508 may first cut a straw bale into small pieces (e.g.,with a Common Off The Shelf (COTS) straw chopper). A blower may sendsthe cut straw upwards to the roof, and into the pasteurization tank. Thepasteurization tank may have a straw catch area to allow for the blownstraw to settle and prevent clogging.

FIG. 6A illustrates a substrate pasteurization system according to anembodiment of the disclosure. Pasteurized substrate may include one ormore mediums capable of accepting fungi spore and supporting growth offungi (e.g., straw, wood chips, sawdust, cardboard, coffee grounds, andother cellulose-based substrates.) Pasteurization tank 602 may containouter tank 604, inner tank 605, water mixer 606, and water input 608.Pasteurization tank 602 may be operatively connected to substrate input(e.g., hay blower tube) 612, stir and output auger 610, master outputvalve 620, drain and cool auger tube 618, and water drain 616. Innertank 605 may contain one or more perforations 614 allowing apasteurization solution to circulate between inner tank 605 and outertank 604.

According to some embodiments, substrate (e.g., straw) may be blown intoinner tank 605, which may contain a stir and output auger 610 to eitherstir the substrate or force it through a bottom orifice 622. The bottomorifice 622 may be of varying sizes (e.g., approximately 2″wide, 4″wide, etc.) and may be controlled by master output valve 620 (e.g., aball valve). Inner tank 605 may be perforated to allow water, but notsubstrate, to flow between inner tank 605 and outer tank 605. The sizingand spacing of these perforations may facilitate pasteurization.According to some embodiments, outer tank 604 may encapsulate inner tank605 in such a way that a water level can rise above the top of innertank 605. This may allow substrate to be forcibly dunked into water.According to some embodiments, a heater and water drain may be in outertank 604 but not inner tank 605. Water mixer 606 (e.g., a circulationpump) may circulates water from inner tank 605 to outer tank 604(keeping a pressure low on the inside tank to improve water flow). Insome embodiments, outer tank 604 can be a modified COTS tank (it ispossible that the inner tank 605 can be as well). Outer tank 604 mayreceive water from a water holding tank, and may drain to a water draintank. When the substrate is finished, the water is first drained andthen an auger (e.g., stir and output auger 601) in inner tank 605 mayforce wet substrate through the bottom orifice and into the coolingsection (e.g., drain and cool auger tube 618).

FIG. 6B illustrates a substrate pasteurization tank according to anembodiment of the disclosure. As illustrated in FIG. 6B, agitator 624may include blades 626. Agitator 624 may be an auger which may turn afirst direction to stir substrate and an opposite direction to expelsubstrate from a pasteurization tank. As illustrated, agitator motor 630may be mounted on top of a tank and agitator 624 may be suspended byconnector 628 (e.g., a thrust bushing).

FIG. 6C illustrates a substrate pasteurization tank according to anembodiment of the disclosure. As illustrated in FIG. 6C agitator motor630 may be mounted on mount 632 to pasteurization tank lid 634.Pasteurization tank lid 634 may include vent 636 which may permit anescape of blower/loader air. A top of a pasteurization tank may includea water fill port 640 and a tank access port 638. Tank access port 638may permit access to a pasteurization tank to insert a probe to checktemperature levels, water levels, or for other measurements. Temperaturecontroller 646 may be mounted on a side of tank, according to someembodiments. Heater 648 may be an immersion heater which may be insertedvia a side port into a pasteurization tank. A pasteurization tank may besupported by legs 650. A pasteurization tank may drain via valve 652which may have a master valve 654 and a drain port 656. Drain port 656may allow for the draining of water while valve 652 keeps substrate fromdischarging. When water has drained (after pasteurization of substrate)valves 652 and 654 may be opened and an internal agitator or auger maybe used to discharge pasteurized substrate to a conveyor.

FIG. 6D illustrates a substrate pasteurization tank lid according to anembodiment of the disclosure. As illustrated port 658 may provide accessfor an agitator shaft via mount 632 and tank lid 634. Vent 636 may beopened or closed (e.g., open during a blowing process and closed orpartially closed during pasteurization). Vent 636 may be screened toallow for the escape of air but not the discharge of substrate.

FIG. 6E illustrates a substrate pasteurization tank lid according to anembodiment of the disclosure. Pasteurization tank lids may be differentdiameters in different embodiments.

FIG. 6F illustrates a substrate pasteurization tank lid according to anembodiment of the disclosure. substrate pasteurization tank lid 634 mayinclude vent 636. In some embodiments, a vent may be provided on aseparate portion of a pasteurization tank and substrate pasteurizationtank lid may not contain a vent.

FIG. 6G illustrates a substrate pasteurization tank orifice adapteraccording to an embodiment of the disclosure. Valve 652 may have anupper portion for fitting to a bottom of a pasteurization tank and alower portion for discharging pasteurized substrate.

FIG. 6H illustrates a substrate pasteurization tank orifice adapteraccording to an embodiment of the disclosure. Valve 652 may contain aninner valve or mechanism for allowing the draining of water whileretaining all, substantially all, or a portion of the substrate.

FIG. 6I illustrates a substrate pasteurization tank orifice adapteraccording to an embodiment of the disclosure. As illustrated in FIG. 6I,drain port 656 may allow draining of water or other solutions frompasteurized substrate.

FIG. 6J illustrates a substrate pasteurization tank substrate supplyduct according to an embodiment of the disclosure. Port 642 may join apasteurization tank top to allow a flow of chopped substrate into atank. Port 644 may provide a connector for a blower hose to receiveblown, chopped substrate according to an embodiment. In someembodiments, port 644 may be shaped to form a scoop or funnel forreceiving manually or automatically fed chopped substrate.

FIG. 6K illustrates a substrate pasteurization tank agitator 624 andblades 626 according to an embodiment of the disclosure.

FIG. 6L illustrates a substrate pasteurization tank agitator 624 andblades 626 according to an embodiment of the disclosure.

FIG. 6M depicts a cross-sectional view of a substrate pasteurizationtank according to an embodiment of the disclosure. Straw can bepasteurized to be an effective substrate for fungi (e.g., mushrooms).Improperly pasteurized straw may contain too many microorganisms toallow the mushroom mycelium to grow properly in their early stages ofdevelopment, or they can grow too slowly.

Pasteurization can be a first step in the prep room. Chopped straw canbe fed into a pasteurization tank from the straw storage room, either byhand or with a chopper/blower. Then, water can be preheated (e.g., usinga propane water heater) and fed into a tank on top of dry chopped straw.Feeding the water in the top may prevent straw from floating to thesurface and may ensure that straw is thoroughly saturated with water.

Once the tank is filled with water, one or more tank heaters (e.g., fourimmersion heaters) may be controlled by a temperature controller andprobe to keep the tank at a constant temperature. If temperature is hardto maintain in some environments, insulation can be added to the tankdesign.

The agitator/auger inside a pasteurization tank can be turned backwardsduring soaking to ensure even mixing. After soaking, an agitator/augercan be turned forwards to force the straw out the bottom of the tank.

The agitator/auger may be turned by a standard AC gear motor. Anagitator/auger can be left unsupported inside the tank, and may simplyrests on the lid section with a shaft collar.

As the straw is ejected from the pasteurization tank, a conveyor belowthe tank valve 654 can be turned on. Both the conveyor and the auger forthe pasteurization tank can be controlled by a switch on the wall wherean operator can stand. This allows the operator to coordinate thebagging with the substrate exiting the tank and allow the operator toensure an even flow of substrate.

A conveyor can be gently inclined to get from the ejection point of thetank (e.g., tank valve 654) to an intake of the bagging system. Theconveyor may be cleated. It some embodiments, a conveyor may include oneor more guards and other systems to ensure the substrate stays on duringtransport (and to encourage drainage if necessary).

A bagging and inoculation system as illustrated in FIG. 1F may includebagger 180, inoculation system 190 and conveyor 178, according to anembodiment of the disclosure. Conveyor 178 can carry the wet substrateinto the intake hopper of an a bagging machine. The bagging machine canincludes an automatic bag weigher that fills the bags to a sameapproximate level every time. A level may be configurable.

As the substrate passes into the bag, a passive inoculation system canbe triggered. This may include a basic spoked wheel that is turned bythe passing substrate underneath and releases grain spawn from a hopperas it turns.

FIG. 7 illustrates an alternative substrate pasteurization systemaccording to an embodiment of the disclosure. As illustrated in FIG. 7,wire cage 712 may be used to submerge, via pulley system 704, substrateinto container 702 for pasteurization. Container 702 may contain waterdrain 710 and heater 706. Container 702 may rest on rolling base 714 fortransport. Substrate may be prepared by chopper 708.

FIG. 8 illustrates another alternative substrate pasteurization systemaccording to an embodiment of the disclosure. Wire basket 806 may beused to pasteurize substrate in a pasteurization tank via a pulley. Apasteurization tank may be supported on a roller system 808. Apasteurization tank may include a heater 810. A container 802 maysurround a pasteurization tank. Rain catch tank 804 may be on a roof ofcontainer 802 and may provide water for pasteurization. Solar waterheater 814 may also be present on a roof of container 802. Substrate maybe prepared by chopper 812.

FIG. 9 depicts a substrate preparation and packaging system according toan embodiment of the disclosure. Preparation room 902 may include apacking station 904 and a cool and drain conduit 906. Cool and drainconduit 906 may convey substrate from pasteurization tank 912, which maybe on a roof of preparation room 902. Pasteurization tank 912 mayinclude heater 908 and may receive water from water tank 910. Water tank910 can be an intermediate bulk container or IBC tote, or it can becustomer insulated steel. Pasteurization tank 912 may receive substratefrom chopper 914. In some embodiments, the preparation room 902 keepsdry straw out of the work area.

FIG. 10 depicts a substrate preparation and packaging system accordingto an alternative embodiment of the disclosure. Preparation room 1002may include pasteurization tank 1010, substrate input 1012, heatingelement 1004, and conveyer 1008. Alternatively, heating elements can belocated in the tank to heat water before the water is mixed with thesubstrate. A pump can also be attached to the tank to recirculate, asnecessary. Substrate may be prepared by chopper and blower 1006. In someembodiments, rate matching is used in substrate preparation. Ratematching refers to matching the rates at which the substrate is choppedand fed into the processing area with the rate that the paddle conveyorturns such that the feed and conveyor are balanced. In some embodiments,a strawpacitor, or sensing mechanism, is used to match the speed thespeed of the incoming substrate with the speed of the conveyor.

FIG. 11 shows an illustrative flow diagram of process 1100 for preparingsubstrate according to an embodiment of the disclosure. FIG. 11 is ahigh level flow diagram showing processes including substrate chopping,cold soaking of substrate, heating of substrate, and packing ofsubstrate. At block 1102 the process 1100 may begin. Preparation ofsubstrate such as, for example, chopping of hay or other substrate mayoccur at block 1104. At block 1106 substrate may be soaked in a coldsolution (e.g., water) for a specified period of time (e.g., 48 hours).At block 1108 substrate may be heated for a specified period of time(e.g., 48 hours). After heating substrate may be drained, inoculated,and packed at block 1110. At block 1112, the process 1100 may end.

FIG. 12 depicts an alternative container 1202 for pasteurizing substrateaccording to an embodiment of the disclosure. Container 1202 may includea main body 1204, a valve including valve control 1206, and a orifice1208 for dispensing pasteurized substrate. Container 1202 may include aninternal agitator (not shown) such as, for example, a grain flipper.

FIG. 13 depicts a containers for water according to an embodiment of thedisclosure. In some embodiments, containers 1302 may be stored on a roofof a grow container and or adjacent to a grow container. Containers 1302may be supported by support frames 1304. Containers 1302 may includeinput covers 1306 and dispensing valves 1308. Containers 1302 mayinclude an internal agitator (not shown) such as, for example, a grainflipper.

FIG. 14 depicts an alternative container 1402 for pasteurizing substrateaccording to an embodiment of the disclosure. Container 1402 may includeinput line 1404, output valve 1406 and one or more gauges 1408. Gauges1408 may indicate temperature, pressure, or other substrate or solutioninput conditions.

FIG. 15 is a diagram showing an arrangement of containers for water,pasteurization, water reclamation, and misting according to anembodiment of the disclosure. Grow container 1502 may support holdingtank 1504 which may supply fluids to pasteurization tank 1506.Pasteurization tank may drain fluids (e.g., water) into drain tank 1510.Misting in grow container 1502 may be supplied by mist tank 1508.

FIG. 16 shows a schematic arrangement of a pasteurization container, asubstrate cooling and drying apparatus, and a substrate packing supplypassage according to an embodiment of the disclosure. Pasteurizationtank 1604 may drain water into drain 1606. Pasteurized substrate may betransported from pasteurization tank 1604 up auger tube 1608 by an augerdriven by motor 1610. A slope of auger tube 1608 may encourage drainingto drain 1606 while cooling substrate conveyed upwards by an auger maybe supplied to packing supply tube 1612. According to some embodiments,packing supply tube 1612 may be a substantially vertical tube fortransferring substrate to an inoculation and packing system.

Inoculation

Inoculation may involve inserting fungi spores into a substrate.Different methods and different types of spores may be used depending ona type of fungi to be grown, a substrate used, and other factors.Inoculation may, for example, be performed by mixing a grain spawn intoa substrate (e.g., dispensing grain spawn via a hopper into a growcontainer or grow bag). Inoculation may also be performed by injecting aliquid culture into a substrate (e.g., injecting a liquid culture into agrow bag at one or more locations).

FIG. 17 depicts an inoculation and packing apparatus according to anembodiment of the disclosure. According to some embodiments, one or moreportions of a packing and inoculation infrastructure may be integratedinto a packing tube 1704. In some embodiments, a packing tube maydescend into a preparation area from a rooftop pasteurization system. Apacking system may consist largely of one or more sliders (e.g., upperand lower sliders) that determine a size of one layer of the substrateto be packed. For example, a bottom slider or other mechanical dividermay form a barrier in a portion of a packing tube. Substrate may rest onthis mechanical divider and until an adequate portion has been stacked.A top mechanical divider or slider may determine a size of a substrateportion to be packed by sealing off a flow of substrate into a packingtube once a specified amount of substrate has been accumulated on alower mechanical divider or slider. In parallel with these mechanicaldividers or sliders one or more other sliders may control injection ofthe grain spawn into the substrate. The combined packing/inoculationsystem layers the substrate with the spawn to fill the grow containers1726 (e.g., bags). According to some embodiments, grow containers may bebetween 10″ and 14″ diameter cylinders and approximately 24″ tall. Growcontainers may be provided in other diameters and heights. Asillustrated, one or more mechanical dividers or sliders may be driven bypneumatic cylinders 1706 or other actuators. Pneumatic cylinders 1706 orother actuators may be communicatively coupled to a control system 1724,which may determine an amount of substrate per growing unit, a number ofinoculations, an amount of grain spawn, and other factors. In someembodiments, a grow container may not be inoculated via a pneumaticcylinder or other actuator. In some embodiments, grain spawn may bedispensed from a grain spawn hopper 1730 or another container into agrow container. Grain spawn hopper 1730 may be communicatively coupledto control system 1724. Control system 1724 may coordinate the timing ofdispersal of grain spawn from grain spawn hopper 1730 with the timing ofa slider or divider so that grain spawn may be dispersed in one or morelayers in a grow container.

Growth Environment

The growth environment may be a modified shipping container, altered toprovide an optimized environment for preparing fungi growth bags orother containers, monitoring the and controlling the growth of fungi,and harvesting fungi. A growth environment may be divided into aplurality of areas to allow separate growth bag preparation areas andone or more grow areas. One or more airlocks may be provided to reducecontamination. A growth preparation area may provide space and/orapparatus for one or more of preparing substrate, pasteurizingsubstrate, inoculating substrate, and packing substrate. A growingcontainer may contain a control system for regulating and/or monitoringa growth environment.

FIG. 18A depicts a growing container control system according to anembodiment of the disclosure. Grow container control system 1802 mayinclude control center 1806, CPU interface 1808, and wireless interface1804 to allow user 1812 to access the system remotely. Control center1806 preferably monitors and controls all of the components based onspecifications set by user 1812. For example, control center 1806 canmonitor a climate control system and change humidity, carbon dioxidelevels, temperature, and other factors in order to remain withinuser-specified measurements. In yet another example, control center 1806can be coupled to the ventilation system to ensure the proper airflow isbeing maintained for various sections of fungi. The above are justillustrative examples of components that can be monitored and controlledin order to ensure maintenance of optimal growing conditions specifiedby the user.

CPU interface 1808 allows user 1812 to have direct access to controlcenter 1806, and wireless interface 1804 allows user 1812 to have remoteaccess to control center 1806. Either connection allows user 1812 tomodify any pre-set levels, override pre-set levels, or simply monitoractivity in a container. Wireless interface 1804 allows for controlcenter 1806 to provide remote alerts to user 1812, giving user 1812 theability to change or override any preset characteristics. In anotherembodiment, the wireless connection allows for an additional party, suchas off-site harvest expert or growing expert 1810, to communicate withuser 1812 and review all of the data and conditions that are availableto user 1812.

One of ordinary skill in the art would recognize that the monitoringsystem could monitor, control, and change any additional components thataffect the environment or feeding conditions. In order to maintainconditions or provide alerts, control center 1806 can include algorithmsrelating to environmental conditions prescribed by the user. In oneembodiment, control center 1806 utilizes a series of if-thenrelationships to maintain optimal conditions. For example, if humiditywithin a container falls below a specified amount, then control center1806 activates the humidifier until the humidity level stabilizes. Inanother example, if the temperature within container rises above orbelow a specified level, then control center 1806 activates a climatecontrol system until the temperature stabilizes. A monitoring system canalso be configured to capture visual records of fungi growth, and recordand report all data points for conditions that the monitoring systemcontrols. The system may also be configured to issue alerts based on theif-then relationships described above to alert the user of systemfailures, changes in conditions, or other variations from levelsprescribed by the user. All of these variables can be changed based onthe crop desired and the optimal environmental and feeding conditionsfor that crop.

FIG. 18B depicts a grow container electrical diagram according to anembodiment of the disclosure. As illustrated, A/C power may be convertedto D/C power and provided to a plurality of components, such as, forexample, one or more controllers, humidity sensors, CO₂ sensors,temperature sensors, air conditioning, lights, grow lights, misters,fans, carousels (e.g., motors), a misting pump, a water pump, one ormore heaters, valves, agitators, augers, conveyors, baggers, vents,inoculation systems, etc. Control signals may be sent from and receivedby one or more controllers. Signals may be sent to or received fromsensors (humidity, temperature, CO₂, fluid levels, weights, etc.), airconditioning, lights, heaters, fans, carousels, valves, agitators,augers, conveyors, baggers, misters, pumps, vents, inoculation systems,and other components. Water and/or other fluids may be received from orsupplied to one or more components such as, for example, pumps,containers, valves, a pasteurization tank, a water heater, a drain, aholding tank, a waste tank, a mister, etc.

FIG. 19A depicts a growth medium support structure according to anembodiment of the disclosure. According to some embodiments, growthmedium support structures may provide vertical racks, shelves, orplatforms for supporting one or more containers or bags of pasteurizedand inoculated substrate (e.g., grow bags). Grow bags may be supportedon a growth medium support structure 1902 (e.g., 3 feet tall carouseltrees). The growth medium support structures may each contain aplurality of bags, stacked on top of each other, directly below hangingpoint 1904. Each grow room may have a motorized carousel that carriesthe bags to a user one growth medium support structure at a time. Eachgrowth medium support structure may have a plurality of trays orplatforms 1906 and 1908 for supporting grow bags.

FIG. 19B depicts a growth medium support structure according to anembodiment of the disclosure. The growth medium support structures(e.g., grow trees) can be made from self-jigging sheet metal punched andwelded together. Each grow tree may consist of a series of pentagonalflat pieces to support the grow bags, and sides to provide lift andstiffness. Holes can be provided in the support structure in case it isnecessary to support the grow bags laterally (i.e., they can be tiedin).

The carousels may allow the operator to remain standing in a singleplace while accessing the entire crop in multiple grow rooms during thegrow period and for loading and harvest times. The carousels can becontrolled by Forward/Reverse controllers that may be integrated withthe carousels (e.g., customized PACLINE carousels). Grow trees can bemounted to the carousel load bars with swivel hooks (not shown) suchthat the operator can rotate each grow tree independently.

FIG. 20 depicts a growth medium support structure conveyor arrangementaccording to an embodiment of the disclosure. As depicted in FIG. 20, aseparate conveyor or carousel may be utilized for each growing area of acontainer 2002. For example, a first growing area may contain carousel2004 powered by motor 2008 and a second growing area may containcarousel 2006 powered by motor 2010.

FIG. 21 depicts an alternative growth medium support structure conveyorarrangement according to an embodiment of the disclosure. As depicted inFIG. 21, in some embodiments, a single carousel 2014, powered by motor2016, may be utilized for multiple growing areas of container 2102.

Remote Monitoring and Management

Remote monitoring and management may provide a user interface formonitoring one or more conditions of a growing container. Variables thatmay be monitored include, but are not limited to, air temperature, airflow, carbon dioxide levels, water temperature, pH level, and nutrientconductivity. Remote monitoring may include one or more audio and/orvideo feeds. Remote management may allow control of one or moreenvironmental conditions including, but not limited to, air temperature,air flow, carbon dioxide levels, water temperature, pH level, andnutrient conductivity. As discussed in further detail with respect toFIGS. 22-25 below, one or more user interfaces may be provided tomonitor and/or control one or more environmental variables.

FIG. 22 shows examples of data that can be remotely monitored andcontrolled via the illustrative monitoring system, all according toembodiments of the disclosure. For example, FIG. 22 illustrates variousvent cycle characteristics 2202 that can be remotely set and modifiedwith respect to the vents in an embodiment of the disclosure.

FIG. 23 shows further examples of data that can be remotely monitoredand controlled via the illustrative monitoring system, all according toembodiments of the disclosure. As shown in FIG. 23, when a system isselected, an exemplary set of icons 2302, 2304, 2306, pertaining to theselected system are displayed. For example, if the tank pump system isselected, an embodiment of a monitoring system might displayrelationship icon 2302, cycle icon 2304, and alarm icon 2306.Relationship icon 2302 describes the relationship that has been set upto determine what conditions should occur for a corresponding action tobe triggered. Cycle icon 2304 allows the user to specify the number orfrequency of cycles to run a particular system. Alarm icon 2306 allowsthe user to specify the scenarios for which a monitoring system shouldalert the user for a particular system.

FIGS. 24A-24D show examples of additional data that can be remotelymonitored and controlled via the illustrative monitoring system, allaccording to embodiments of the disclosure. FIG. 24A shows a screen shotof exemplary air and water data that can be reported to the user. Suchdata can include air temperature 2402, air flow 2404, carbon dioxidelevels 2406, water temperature 1708, pH level 1710, and nutrientconductivity 1712. 24B shows a live video feed 1714 of fungi. Amonitoring system can also provide video feeds of other zones of cropsbeing grown in a container in order to allow a user to monitor differentzones of different crops or different zones of the same crop. FIG. 24Cshows an example of alarm function 1716 in a monitoring system. In thisexample, the user has configured alarm function 1716 to notify the userwhen the air temperature has exceeded 82 degrees F. or has dropped below64 degrees F. FIG. 24D illustrates additional systems 1718 that can beremotely monitored and controlled.

FIGS. 25A-25B show examples of further data that can be remotelymonitored and controlled via the illustrative monitoring system, allaccording to embodiments of the disclosure. FIG. 25A shows systems 1720that can be monitored by cycles, and 25B shows an example of thecontrols 1722 for setting cycles for a particular system.

FIG. 26 shows a perspective view of an embodiment of a ventilationsystem. The ventilation system can also include tube 2602, which mayspan along the floor of a container in any direction. In one embodimentof the disclosure, tube 2602 is positioned between, and is parallel to,a carousel supporting growth medium support structures. Tube 2602includes end 2604, which is configured to receive a fan unit (notshown), as well as perforations (not shown) along the length of tube2602. When the fan unit (not shown) is turned on, air is circulatedalong the length of tube 2602, and is released upward through theperforations (not shown) along tube 2602 as an alternative or additionalvertical air source. One of ordinary skill in the art would recognizethat air can flow vertically from either the ceiling to the floor, orfrom the floor to the ceiling, of a container. One of ordinary skill inthe art would also recognize that air flow in the horizontal andvertical directions is just an example and the embodiment is not limitedto only two directions, nor is it limited to those two particulardirections.

The system can be configured to produce fungi, and all plants includingroot crops. For example, the system can produce: all types of lettuce;all types of herbs such as basil, oregano, mint, parsley, rosemary,thyme, and chive; all types of leafy greens such as kale, chard, spinachand arugula; all vine crops such as strawberries, tomatoes, and peppers;cucumbers; and mushrooms. One of ordinary skill in the art wouldrecognize that these are just examples of non-root crops, and thedisclosure is not meant to be limited to these exemplary crops only. Thesystem can also be configured to utilize fish tanks in order to raisevarious forms of seafood, such as fish, shrimp and lobsters.

The disclosed system can provide the utmost efficiency as fungi can beharvested and new fungi can begin the cycle all in the same space at thesame time.

Although the above description describes embodiments of the invention,it should be understood that the techniques and concepts are applicableto growing systems in general. Thus the invention may be embodied inother specific forms without departing from the spirit or essentialcharacteristics thereof.

While the above describes a particular order of operations performed bya given embodiment of the invention, it should be understood that suchorder is exemplary, as alternative embodiments may perform theoperations in a different order, combine certain operations, overlapcertain operations, or the like. References in the specification to agiven embodiment indicate that the embodiment described may include aparticular feature, structure, or characteristic, but every embodimentmay not necessarily include the particular feature, structure, orcharacteristic.

While the present invention has been described in the context of amethod or process, the present invention also relates to apparatus forperforming the operations herein. This apparatus may be speciallyconstructed for the required purposes, or it may include ageneral-purpose computer selectively activated or reconfigured by acomputer program stored in the computer. Such a computer program may bestored in a computer readable storage medium including, withoutlimitation, any type of disk including optical disks, CD-ROMs, andmagnetic-optical disks, read-only memory (ROM), random access memory(RAM), magnetic or optical cards, or any type of media suitable forstoring electronic instructions.

1. A system for generating high-yield fungi production, the systemcomprising: at least one modular container; a growing system housedwithin the modular container, the growing system comprising: a substratepreparation system configured to accept substrate and prepare substratefor pasteurization; a pasteurization system configured to pasteurizeprepared substrate received from the substrate preparation system; adraining, cooling, and packing system configured to cool and drainpasteurized prepared substrate from the pasteurization system and topack pasteurized and cooled substrate into at least one growingcontainer; an inoculation system configured to inoculate the pasteurizedand cooled substrate; a plurality of vertical racks coupled to a ceilingof the modular container and configured to hold the at least one growingcontainer, a misting system configured to provide humidity and water tothe at least one growing container; a climate control system configuredto control environmental conditions inside the modular container; aventilation system configured to provide the at least one growingcontainer with airflow; and a monitoring system coupled to the growingsystem, the monitoring system configured to monitor and control thepasteurization system, climate control system, ventilation system andmisting system in order to maintain a set of conditions prescribed by auser, wherein the monitoring system is configured to provide the userwith real-time alerts and access to the growing system.
 2. The system ofclaim 1 further comprising a lighting system coupled to a ceiling of themodular container and configured to provide artificial light for the atleast one growing container.
 3. The system of claim 1 further comprisingmonitoring and controlling a level of CO₂ within the modular container.4. The system of claim 1, wherein the pasteurization system comprises aninner tank and an outer tank, wherein the outer tank includes a heaterand a water drain and wherein the inner tank is configured to holdsubstrate material and the inner tank is positioned within the outertank, the inner tank containing one or more openings allowing watercirculation between the inner tank and the outer tank.
 5. The system ofclaim 4, wherein the draining, cooling, and packing system comprises: anauger at least partially within the inner tank, wherein the auger isoperable to agitate substrate materials in the inner tank and tofacilitate drainage of water from the inner tank to the outer tank viaat least one opening in the inner tank; a drain in the outer tankoperable to permit drainage of water from the outer tank; an inclineddraining and cooling tube to convey pasteurized substrate from the innertank; a valve connected to the inner tank at a first end and connectedto a lower end of the inclined draining and cooling tube at a secondend, wherein the valve is operable to control a flow of substrate frominner tank to the inclined draining and cooling tube; an auger withinthe inclined cooling and draining tube operable to convey pasteurizedsubstrate from the lower end of the inclined drain and cool tube to anupper end of the inclined drain and cool tube; a drain connected to alower end of the inclined drain and cool tube, the drain operable toreceive water draining from the inclined drain and cool tube; and apacking supply tube connected at a proximate end to the upper end of theinclined drain and cool tube and operable to convey pasteurizedsubstrate from the proximate end to a distal end, the packing supplytube including at least one sealing wall operable to control a flow ofpasteurized substrate through the packing supply tube.
 6. The system ofclaim 1, wherein the inoculation system comprises at least one needleand an inclined hollow tube oriented to inoculate the pasteurized andcooled substrate with grain spawn, the inclined tube having a closureoperable to control a flow of the grain spawn to the pasteurized andcooled substrate.
 7. The system of claim 1, wherein the modularcontainer comprises a plurality of dividers separating the modularcontainer into a plurality of areas.
 8. The system of claim 1, where theplurality of areas comprises: at least two growing areas; a preparationarea, an airlock operable to reduce contamination to the growing systemfrom outside of the modular container, wherein the airlock provides theuser access to the preparation area from outside of the modularcontainer.
 9. The system of claim 1, wherein the plurality of verticalracks coupled to the ceiling of the modular container are coupled to theceiling of the modular container via a conveyor, further wherein theconveyor supports the plurality of vertical racks within a growing areaand wherein the conveyor provides the user access to the plurality ofvertical racks from a preparation area.
 10. The system of claim 1wherein the monitoring system further comprises a control center, CPUinterface, and wireless interface, further wherein the monitoring systemis configured to: remotely provide the user with data on the growingsystem; and allow the user to remotely alter the performance of at leastone of the misting system, the climate control system, and theventilation system, in order to maintain the set of conditionsprescribed by the user.
 11. A method for generating high-yield fungiproduction in any environment, the method comprising: configuring atleast one modular container for fungi cultivation; assembling a growingstation within the modular container, assembling the growing stationfurther comprising: assembling a substrate preparation system configuredto accept substrate and prepare substrate for pasteurization; assemblinga pasteurization system configured to pasteurize prepared substratereceived from the substrate preparation system; assembling a draining,cooling, and packing system configured to cool and drain pasteurizedprepared substrate from the pasteurization system and to packpasteurized and cooled substrate into at least one growing container;assembling an inoculation system configured to inoculate the pasteurizedand cooled substrate in the at least one growing container; assembling aplurality of vertical racks coupled to the ceiling of the modularcontainer and configured to hold the at least one growing container;assembling a misting system configured to provide humidity and water tothe at least one growing container; assembling a climate control systemconfigured to control environmental conditions inside the modularcontainer; assembling a ventilation system configured to provide theinoculated substrate with airflow; and coupling a monitoring systemcoupled to the growing system, the monitoring system configured tomonitor and control the pasteurization system, climate control system,ventilation system and misting system in order to maintain a set ofconditions prescribed by a user, wherein the monitoring system isconfigured to provide the user with real-time alerts and access to thegrowing system.
 12. The method of claim 11, further comprising:providing a lighting system coupled to a ceiling of the modularcontainer and configured to provide artificial light for the at leastone growing container.
 13. The method of claim 11, further comprisingmonitoring and controlling a level of CO₂ within the modular container.14. The method of claim 11, wherein the pasteurization system comprisesan inner tank and an outer tank, wherein the outer tank includes aheater and a water drain and wherein the inner tank is configured tohold substrate material and the inner tank is positioned within theouter tank, the inner tank containing one or more openings allowingwater circulation between the inner tank and the outer tank.
 15. Themethod of claim 11, wherein the draining, cooling, and packing systemcomprises: an auger at least partially within the inner tank, whereinthe auger is operable to agitate substrate materials in the inner tankand to facilitate drainage of water from the inner tank to the outertank via at least one opening in the inner tank; a drain in the outertank operable to permit drainage of water from the outer tank; aninclined draining and cooling tube to convey pasteurized substrate fromthe inner tank; a valve connected to the inner tank at a first end andconnected to a lower end of the inclined draining and cooling tube at asecond end, wherein the valve is operable to control a flow of substratefrom inner tank to the inclined draining and cooling tube; an augerwithin the inclined cooling and draining tube operable to conveypasteurized substrate from the lower end of the inclined drain and cooltube to an upper end of the inclined drain and cool tube; a drainconnected to a lower end of the inclined drain and cool tube, the drainoperable to receive water draining from the inclined drain and cooltube; and a packing supply tube connected at a proximate end to theupper end of the inclined drain and cool tube and operable to conveypasteurized substrate from the proximate end to a distal end, thepacking supply tube including at least one sealing wall operable tocontrol a flow of pasteurized substrate through the packing supply tube.16. The method of claim 11, wherein the inoculation system comprises: atleast one needle configured to inoculate the pasteurized and cooledsubstrate with a liquid culture; and an inclined hollow tube oriented toinoculate the pasteurized and cooled substrate with grain spawn, theinclined tube having a closure operable to control a flow of the grainspawn to the pasteurized and cooled substrate.
 17. The method of claim11, wherein the modular container comprises a plurality of dividersseparating the modular container into a plurality of areas.
 18. Themethod of claim 11, where the plurality of areas comprises: at least twogrowing areas; a preparation area, an airlock operable to reducecontamination to the growing system from outside of the modularcontainer, wherein the airlock provides the user access to thepreparation area from outside of the modular container.
 19. The methodof claim 11, wherein the plurality of vertical racks coupled to theceiling of the modular container are coupled to the ceiling of themodular container via a conveyor, further wherein the conveyor supportsthe plurality of vertical racks within a growing area and wherein theconveyor provides the user access to the plurality of vertical racksfrom a preparation area.
 20. The method of claim 11, wherein themonitoring system further comprises a control center, CPU interface, andwireless interface, further wherein the monitoring system is configuredto: remotely provide the user with data on the growing system; and allowthe user to remotely alter the performance of at least one of themisting system, the climate control system, and the ventilation system,in order to maintain the set of conditions prescribed by the user.